Packaged air conditioner with vane axial fan

ABSTRACT

A package air conditioning unit includes a housing, a condenser portion including a condenser located in the housing and an evaporator portion located in the housing. The evaporator portion includes an evaporator in fluid communication with the condenser and a vane-axial flow fan rotatable about a fan axis to power airflow from a conditioned space, across the evaporator and back toward the conditioned space.

BACKGROUND

The subject matter disclosed herein relates to residential and commercial packaged air conditioner products. More specifically, the present disclosure relates to supply air fan systems for packaged air conditioner products.

A packaged air conditioner product typically includes a refrigeration circuit having a compressor, condenser and evaporator in fluid communication with each other and circulating a flow of refrigerant or cooling medium therethrough. The components are typically located in a single housing, through which fresh air and/or return air from a conditioned space is circulated and a supply airflow of a selected temperature is output to the conditioned space. Such products are typically installed on a roof of a building, but may also be installed at other locations, such as on the ground.

Generally, the flow of supply air is powered thru the packaged air conditioner by a centrifugal fan, that is either housed or unhoused. Typically, with a centrifugal fan, airflow enters at the center of a fan wheel and turns through a right angle to exit the fan in a radial direction. The airflow is subjected to a centrifugal force resulting in an increase in its static pressure which in turn moves the airflow against the internal resistance within the product as well as external resistance of the ductwork leading to the conditioned space.

One complication of utilizing centrifugal fans in this application is that the centrifugal fans impart angular momentum to the airflow as the airflow exits the fan. The products generally require a wide range of flow rate as well as pressure rise that the fan must work against and an increase in airflow and/or the resistance requires an increase in fan speed. Changes in fan speed vary the amount of angular momentum at the exit of the fan thus varying the flow angle of the airflow leaving the fan. Such variations across the operating envelope of the product cause challenges to maintaining consistent performance across the same operating envelope. These flow angle variations lead to increased product cost due to the addition of air baffles to force a consistent flow angle and/or the added cost due to sub-optimized designs to address the worst case of the flow variations.

In addition, some products are designed to be convertible for supply ducts connecting to the bottom of the housing or at a side of the housing. This convertible configuration further impacts the product design and operation as the total system pressure against which the fan is operating changes depending on the location of the supply duct, changing the fan power of the supply fan and thus overall operating efficiency of the product. Further, with a heating section placed downstream of the fan, the airflow pattern across the heating section changes depending on the location of the supply duct, resulting in a hot spot that changes depending on supply duct orientation. Additionally, the different airflow patterns across the heating section result in different thermal efficiencies and response to safety over-temperature sensing devices depending on the supply duct orientation.

SUMMARY

In one embodiment, a package air conditioning unit includes a housing, a condenser portion including a condenser located in the housing and an evaporator portion located in the housing. The evaporator portion includes an evaporator in fluid communication with the condenser and a vane-axial flow fan rotatable about a fan axis to power airflow from a conditioned space, across the evaporator and back toward the conditioned space.

Additionally or alternatively, in this or other embodiments the vane-axial flow fan is positioned downstream of the evaporator.

Additionally or alternatively, in this or other embodiments the housing includes at least two alternate housing outlets through which the airflow may be directed toward the conditioned space.

Additionally or alternatively, in this or other embodiments a supply duct extends from an airflow outlet of the at least two alternate housing outlets to direct the airflow from the vane axial flow fan to the conditioned space.

Additionally or alternatively, in this or other embodiments the vane-axial flow fan includes a shrouded fan rotor having a plurality of fan blades extending from a rotor hub and rotatable about the fan axis and a fan shroud extending circumferentially around the fan rotor and secured to an outer tip diameter of the plurality of fan blades. A stator assembly is located downstream of the fan rotor, relative to the airflow direction through the vane-axial flow fan. The stator assembly includes a plurality of stator vanes extending between a stator hub and a stator shroud.

In another embodiment, a cooling and/or heating system includes a package air conditioning unit having a housing, a condenser portion including a condenser located in the housing and an evaporator portion located in the housing. The evaporator portion includes an evaporator in fluid communication with the condenser, and a vane-axial flow fan rotatable about a fan axis to power airflow from a conditioned space, across the evaporator and back toward the conditioned space via one or more airflow outlets in the housing. A heating element is located downstream of the vane-axial flow fan to heat the airflow when the package air conditioning unit is operating in a heating mode.

Additionally or alternatively, in this or other embodiments the vane-axial flow fan is positioned downstream of the evaporator.

Additionally or alternatively, in this or other embodiments the housing includes at least two alternate housing outlets through which the airflow may be directed toward the conditioned space.

Additionally or alternatively, in this or other embodiments the two alternate housing outlets are located downstream of the heating elements.

Additionally or alternatively, in this or other embodiments the heating element is one of a gas-fired heat exchanger, electric resistance heaters or a hot water coil.

Additionally or alternatively, in this or other embodiments the vane-axial flow fan includes a shrouded fan rotor having a plurality of fan blades extending from a rotor hub and rotatable about the fan axis and a fan shroud extending circumferentially around the fan rotor and secured to an outer tip diameter of the plurality of fan blades. A stator assembly is located downstream of the fan rotor, relative to the airflow direction through the vane-axial flow fan. The stator assembly includes a plurality of stator vanes extending between a stator hub and a stator shroud.

Additionally or alternatively, in this or other embodiments at least one airflow outlet of the one or more airflow outlets is operably connected to a supply duct to direct the airflow from the vane axial flow fan to the conditioned space.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter is particularly pointed out and distinctly claimed at the conclusion of the specification. The foregoing and other features, and advantages of the present disclosure are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

FIG. 1 is a schematic illustration of an embodiment of a package air conditioning system;

FIG. 2 is a partially exploded view of an embodiment of a blower for a package air conditioning system; and

FIG. 3 is a schematic illustration of another embodiment of a package air conditioning system.

DETAILED DESCRIPTION

Shown in FIG. 1 is a packaged air conditioning unit 10. Air conditioning unit 10 is configured to be mounted at, for example, on a rooftop or alternatively on the ground next to a building. The air conditioning unit is contained in a housing 14 and includes a condenser portion 16 and an evaporator portion 18. The condenser portion 16 includes a compressor 20 for increasing the pressure of a refrigerant and directing the refrigerant to a condenser 22 located in the condenser portion 16. The evaporator portion 18 includes an evaporator 24 and a blower 26 for movement of a supply airflow 28 returned from a conditioned space 30 across the evaporator 24 through which the refrigerant flows to cool the supply airflow 28. The supply airflow 28 is then directed to the conditioned space 30 via a housing outlet 32 and a supply duct 34.

The condenser portion 16 includes a condenser portion inlet 36 and a condenser portion outlet 38. A condenser fan 40 urges an outside airflow 42 into the condenser portion inlet 36, across the condenser 22 and out of the condenser portion outlet 38 to reject heat from the condenser 22.

In some embodiments, the air conditioning unit 10 includes a section downstream of the blower 26, which includes a gas-fired heat exchanger 44, or alternatively a heating coil or an electric resistance heater, located in a supply airflow pathway 46 between the blower 26 and the housing outlet 32. Thus, the air conditioning unit 10 can operate in either a cooling mode or a heating mode. When operating in cooling mode, the supply airflow 28 is cooled by flowing across the evaporator 24, while when operating in heating mode the gas-fired heat exchanger 44 is activated to heat the supply airflow 28 downstream of the blower 26.

Shown in FIG. 2 is a partially exploded perspective view of an embodiment of blower 26, which is a vane-axial flow fan 50. The vane-axial flow fan 50 is located across the supply airflow pathway 46 and may be driven by an electric motor 48 directly connected to the vane-axial flow fan 50 or by a shaft (not shown), or alternatively a belt (not shown) or other arrangement. In operation, the motor 48 drives rotation of the vane-axial flow fan 50 to power the supply airflow 28 thru the vane-axial flow fan 50 and along the supply airflow pathway 46, for example, from the evaporator 24. The vane-axial flow fan 50 includes a casing 52 with a fan rotor 54, or impeller rotably located in the casing 52. Operation of the motor 48 drives rotation of the fan rotor 54 about a fan axis 56. The fan rotor 54 includes a plurality of fan blades 58 extending from a hub 60 and terminating at a fan shroud 62. The fan shroud 62 is connected to one or more fan blades 58 of the plurality of fan blades 58 and rotates about the fan axis 56 therewith. The vane-axial flow fan 50 further includes a stator assembly 64 including a plurality of stator vanes 66, located downstream of the fan rotor 54. The plurality of stator vanes 66 extend substantially radially from a stator hub 68 to a stator shroud 70.

Referring now to FIG. 3, in some embodiments the housing 14 includes two housing outlets, with a first housing outlet 32 a at a bottom panel 72 of the housing 14 and a second housing outlet 32 b at a sidewall 74 of the housing 14. The air conditioning unit 10 is field convertible such that either of the housing outlets 32 a or 32 b can be utilized. The unused housing outlet 32 a or 32 b is closed with a panel (not shown) to prevent leakage from the housing 14. Housing outlet 32 a is connected to the supply duct 34 a to direct the supply airflow 46 a to the conditioned space 30 while housing outlets 32 b is connected to the supply duct 34 b to direct the supply airflow 46 b to the conditioned space 30.

In both embodiments, the vane-axial flow fan 50 is positioned such that the fan 50 is position upstream of the gas-fired heat exchanger 44, and the supply airflow pathways 46 a and 46 b are located downstream of the gas-fired heat exchanger 44.

Use of the vane-axial flow fan 50 as the blower in the packaged air conditioning unit 10 has numerous benefits to the air conditioning unit 10 over the typical centrifugal blower. The stator vanes 66 of the vane-axial flow fan 50 has a benefit of straightening the airflow exiting the fan rotor 54, thus reducing the variation in flow direction due to angular momentum imparted on the airflow due to operation of the vane-axial flow fan 50. There is a secondary benefit in vane-axial flow fan 50 of elimination of flow variation due to fan speed and reduction of variation in pressure loss due to the housing outlet orientation relative to the fan axis. The reduction in flow direction variation reduces temperature variation across the gas-fired heat exchanger 44 and reduces changes to the thermal efficiency of the gas-fired heat exchanger 44 depending on either the speed of the fan and the two alternate supply airflow paths. The reduction in flow direction variation makes the pressure drop thru the two alternate supply airflow paths the same which makes the unit's capacity & efficiency the same for the two alternate supply airflow paths.

While the present disclosure has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the present disclosure is not limited to such disclosed embodiments. Rather, the present disclosure can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate in spirit and/or scope. Additionally, while various embodiments have been described, it is to be understood that aspects of the present disclosure may include only some of the described embodiments. Accordingly, the present disclosure is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims. 

1. A package air conditioning unit, comprising: a housing; a condenser portion including a condenser disposed in the housing; an evaporator portion disposed in the housing including: an evaporator in fluid communication with the condenser; and a vane-axial flow fan rotatable about a fan axis to power airflow from a conditioned space, across the evaporator and back toward the conditioned space.
 2. The packaged air conditioner of claim 1 wherein the vane-axial flow fan is positioned downstream of the evaporator.
 3. The package air conditioning unit of claim 1, wherein the housing includes at least two alternate housing outlets through which the airflow may be directed toward the conditioned space.
 4. The package air conditioning unit of claim 3, wherein the at least two alternate housing outlets are operably connected to a supply duct extending therefrom to direct the airflow from the vane axial flow fan to the conditioned space.
 5. The package air conditioning unit of claim 1, wherein the vane-axial flow fan includes: a shrouded fan rotor including: a plurality of fan blades extending from a rotor hub and rotatable about the fan axis; and a fan shroud extending circumferentially around the fan rotor and secured to an outer tip diameter of the plurality of fan blades; and a stator assembly located downstream of the fan rotor, relative to the airflow direction through the vane-axial flow fan, the stator assembly including a plurality of stator vanes extending between a stator hub and a stator shroud.
 6. A cooling and/or heating system comprising: a package air conditioning unit configured to operate in at least one of a heating mode and a cooling mode, the package air conditioning unit including: a housing comprising one or more airflow outlets; a condenser portion including a condenser disposed in the housing; an evaporator portion disposed in the housing including: an evaporator in fluid communication with the condenser; and a vane-axial flow fan rotatable about a fan axis to power airflow from a conditioned space, across the evaporator and back toward the conditioned space via the one or more airflow outlets in the housing; and a heating element disposed downstream of the vane-axial flow fan to heat the airflow when the package air conditioning unit is operating in the heating mode.
 7. The system of claim 6, wherein the vane-axial flow fan is positioned downstream of the evaporator.
 8. The system of claim 6, wherein the housing includes at least two alternate housing outlets through which the airflow may be directed toward the conditioned space.
 9. The system of claim 8, wherein the two alternate housing outlets are located downstream of the heating elements.
 10. The system of claim 6, wherein the heating element is one of a gas-fired heat exchanger, electric resistance heaters or a hot water coil.
 11. The system of claim 6, wherein the vane-axial flow fan includes: a shrouded fan rotor including: a plurality of fan blades extending from a rotor hub and rotatable about the fan axis; and a fan shroud extending circumferentially around the fan rotor and secured to an outer tip diameter of the plurality of fan blades; and a stator assembly located downstream of the fan rotor, relative to the airflow direction through the vane-axial flow fan, the stator assembly including a plurality of stator vanes extending between a stator hub and a stator shroud.
 12. The system of claim 6, wherein at least one of the one or more airflow outlets is operably connected to a supply duct to direct the airflow from the vane axial flow fan to the conditioned space. 